Continuous Pyrolysis Plant

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Continuous Pyrolysis Plant

Continuous pyrolysis plant provides a solution for the large-scale recycling of solid waste. Common types of recyclable waste include oil sludge, discarded plastics, and end-of-life tyres. Their common features are difficulty in reduction and resource utilization. However, continuous pyrolysis technology can solve the above problems. In the pyrolysis reaction, the organic volatile components in the solid waste form pyrolysis oil, carbon black, and syngas. They are high-value products with a wide range of uses.

BLL-30 Fully Continuous Pyrolysis Plant

Basic Information of Beston Continuous Pyrolysis Plant for Sale

Fully continuous pyrolysis plant is the most sophisticated pyrolysis machinery of Beston Group. This kind of equipment applies advanced technology and comprehensive configuration.  The machine has the following features:

BLL-30 Fully Continuous Pyrolysis Machine

  • 24-hour continuous operation working mode;
  • Fully automatic feeding/discharging;
  • Suitable for large-scale solid waste recycling;
  • Standard high-end exhaust dust removal;
  • PLC control.

Below provides you with a detailed parameter table and component diagrams for your reference.

Parameters Table

ModelBLL-30
Capacity30-35t/d
Working ProcessFully continuous
Reactor Sizeφ1800*18500mm
Reactor Material310S stainless steel
Drive SystemZQH650-50 reducer+15kw frequency conversion motor
Land (L*W*H)70m*20m*10m
Power256kw
Burner2.5 million kcal per set
Total Weight of Shipped MaterialsAbout 150t
Number of Containers25m*8m bulk cargo+8*40HQ
Noise (dB)≤60
Heating MaterialsFuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc.
Condensing SystemVertical Condenserφ920*3200
2 sets of vertical condenser
3-in-1 Condenser

Component Diagrams

Side A


BLL-30 Parts Diagram-Side A

Side B


BLL-30 Parts Diagram-Side B

Raw Materials for Continuous Pyrolysis Machine

Oil Sludge for Continuous Pyrolysis

Oil Sludge

Oil sludge is a mixture consisting primarily of petroleum product residues, soil, water, and other impurities. Its main sources are as follows:

  • oilfield drilling and production
  • crude oil gathering and transportation
  • refinery wastewater treatment
01

Waste Plastic for Continuous Pyrolysis

Waste Plastic

Plastic is composed of high molecular polymers. Its main component is petroleum derivatives. The main sources of waste plastic are as follows:

  • domestic waste landfill
  • plastic product manufacturer
  • renewable resources recycling
02

Waste Tyre for Continuous Pyrolysis

Waste Tyre

Tyres are composites made of rubber, steel wire, fiber, and other materials. The sources of waste tyres are quite wide, mainly as follows:

  • end-of-life tyre recycling center
  • transportation & industrial vehicles
  • tyre manufacturer
03

Working Process of Continuous Pyrolysis Plant


Tyre Shredding Production Line
Tyre Shredding Production Line

Raw Material Pretreatment

Continuous pyrolysis reactor has strict requirements on feed size. The waste tyre must be in a rubber powder state, while the feeding size is 1-5mm. We can provide customers with tyre shredding production line. In addition, the feed size of waste plastic is less than 20mm.


Large-inclination Belt
Large-inclination Belt

Raw Material Feeding

At this stage, the materials enter the inert gas protection system through the conveyor. Later, after discharging the excess air, the material enters the reactor through the feeding screw. According to different material status, we provide the following conveying methods.

  • Large-inclination Belt: mainly targeted at solid granular such as tyre rubber powder, plastics particles, and oil sludge with a liquid content of less than 40%.
  • Shaftless Screw: oil sludge with a liquid content of 40%-60%.
  • Oil Slurry Pump: oil sludge with a liquid content of more than 75%.

Continuous Pyrolysis Reactor
Continuous Pyrolysis Reactor

Pyrolysis

Before the raw materials enter, the main furnace requires a 3-4 hour preheating period. At this time, the heat source is provided by the burner. When the temperature reaches 300-350°C, the raw materials enter the pyrolysis furnace and the reaction begins. At this time, the organic volatile matter in the raw material begins to decompose into smaller molecules, forming oil gas. The entire reaction process uses controlled hot air heating.


Oil Gas Condensation System
Oil Gas Condensation System

Oil Gas Condensation

The condenser converts the condensable components in the high-temperature oil gas into pyrolysis oil. Firstly, oil gas passes through a three-stage condensation system. The first stage condenser separates heavy impurities in oil gas. Then, the second/third stage condensers collect different distillate products. The opening & closing of different solenoid valves in the oil pumping pipeline can realize separate & mixed collection.


Water Seal of Continuous Pyrolysis Plant
Water Seal

Syngas Recovery

The non-condensable component of oil gas, syngas, enters the water seal. Water seal purifies syngas. Clean syngas enters the secondary combustion chamber through pipes. It is mixed with high-temperature hot air to heat the main furnace.


High-end Exhaust Gas Treatment System
High-end Exhaust Gas Treatment System

Exhaust Gas Treatment

BLL-30 equipment adopts with high-end exhaust gas treatment system. The high-temperature exhaust gas generated by the entire reaction enters the chemical tower through the induced draft fan. The chemical tower cools, desulfurizes, and denitrifies the exhaust gas. Subsequently, the flue gas enters the electrostatic precipitator and activated carbon precipitator for dust removal. Eventually,  exhaust gas emitted from the chimney meets EU emission standards.


Water-cooled Carbon Black Storage Tank
Water-cooled Carbon Black Storage Tank

Carbon Black Discharging

The solid residue produced by the reaction – carbon black, is extracted through the first spiral discharger. After passing through two water-cooled dischargers, the carbon black enters the temporary storage tank through a bucket elevator. In the temporary storage tank, circulating water cools the carbon black. When the temperature drops below 60 degrees, the carbon black is discharged from the temporary storage tank.

Extensive Application Scenarios for Continuous Pyrolysis Products

The main products from continuous pyrolysis equipment contain pyrolysis oil, carbon black, syngas, and steel wire(from continuous tyre pyrolysis plant only). These sustainable materials have a wide range of applications across various industries. Therefore, these pyrolysis products have considerable economic value. Here are some common application scenarios:

Products Application
Pyrolysis oil Oil can be used as fuel for iron factory, power plant, cement factory, ceramic factory, restaurant, etc.
Pyrolysis oil is reprocessed into Non-standard diesel by a waste oil distillation machine.
Non-standard diesel can be used in heavy oil generators for power generation.
Carbon black Carbon black can be sold directly.
It can be reprocessed into high-quality carbon by the carbon black processing plant.
It is used to make carbon bricks by brick factory.
Steel wire The steel wire can be sold directly.
Syngas It can be used as fuel to heat the reactor.
Pyrolysis Oil
Pyrolysis Oil
Steel Wire
Steel Wire
Carbon Black
Carbon Black
Syn-gas
Syn-gas

Innovative Technologies in Continuous Pyrolysis Machine

Beston Group has many years of experience in equipment design, manufacturing, installation, and operation. Therefore, we have developed mature continuous pyrolysis technology.  Many advanced structures and patented technologies are used in this model. And many key performance parameters are excellent. The following gives you a detailed introduction to innovative technology used in the equipment.

Accurate Control of Feeding System

Accurate Control of Feeding System

The feeding system consists of a double screw conveyor, a sealed silo, and an electronic weighing system with “gram” level accuracy. This enables precise control of the feed volume. In addition, the system can monitor various indicators during the feeding process in real-time. Thus, this enables periodic statistics of the feed.


Reliable Protection of Nitrogen System

Reliable Protection of Nitrogen System

The nitrogen system uses a nitrogen generator with a purity of more than 95%. This device can replace the air in the sealing material bin. During the feeding process, the nitrogen system prevents excess air from entering the reactor with the raw materials. Thus, this maintains an oxygen-depleted environment within the reactor, which makes the pyrolysis process safer.


Precise Adjustment of Reaction Temperature

Precise Adjustment of Reaction Temperature

The induced draft fan reintroduces the high-temperature flue gases into the combustion chamber. At the same time, the high-temperature exhaust gas is mixed with the high-temperature hot air provided by the burner in the combustion chamber. Therefore, the accurate ratio of mixed air volume enables precise adjustment of reaction temperature.


Triple Anti-coking of Continuous Pyrolysis Reactor

Triple Anti-coking of Reactor

Coking in pyrolysis reactions, especially in oil sludge pyrolysis, seriously affects pyrolysis efficiency. Our equipment applies the following anti-coking methods:

  • Reusing high-temperature flue gas reduces the temperature difference of the reactor to prevent coking;
  • High-temperature catalyst prevents the material from coking during the rapid reaction time.
  • Mesh chain in the furnace contacts and friction with the inner wall of the reactor to physically remove the coke.

Self-cleaning of Three-stage Condenser

Self-cleaning of Three-stage Condenser

Three-stage condenser realizes the separation of heavy impurities and efficient collection of pyrolysis oil. In addition, BLL-30’s condenser uses self-cleaning technology. The oil pump regularly circulates the hot oil in the oil tank to flush the condensation tube in the condenser. This avoids the problem of condensation pipe clogging during long-term use.


Real-time Sampling of Discharge System

Real-time Sampling of Discharge System

The discharge system utilizes a combination sealing design and a water-cooled sealing slag box. It prevents leakage of high-temperature oil and gas during the continuous slag discharge process. Additionally, The discharge head adopts a residue sampling structure. Customers can thus detect the pyrolysis residues in the reactor at different times.


Intelligent Monitoring of Operation

Intelligent Monitoring of Operation

Through PLC control, the system can centrally control parameters such as start and stop, temperature, and pressure of all equipment. ; At the same time, IoT technology enables real-time remote monitoring of the entire system. Operators can monitor the operating status of the equipment in real-time and make timely adjustments and responses.

Comparison of 3 Production Modes: Continuous Vs. Batch Vs. Skid-mounted

Continuous Type

Working period: work continuously 24 h/day
Structure: partial system with modular structure
Capacity: 13-30 T/D
Fundamental work: need
Reactor cooling time: not required
Automation level: High
Installment period: 25-45 working days

Batch Type

Working period: one furnace per day
Structure: partial system with modular structure
Capacity: 5-10 T/D
Fundamental work: need
Reactor cooling time: need
Automation level: medium
Installment period: 20-40 working days

Skid-mounted Type

Working period: one furnace per day
Structure: modular structure
Capacity: 2-3 T/D
Fundamental work: not required
Reactor cooling time: need
Automation level: medium
Installment period: 3-5 working days

Beston-Continuous-Pyrolysis-Plant-for-Sale
Beston Continuous Pyrolysis Plant for Sale
Beston Small Pyrolysis Plant for Sale
Beston Small Pyrolysis Plant for Sale
Beston Mini Skid-mounted Pyrolysis Plant for Sale
Beston Mini Skid-mounted Pyrolysis Plant for Sale

Pyrolysis Projects of Beston Group Worldwide

As a solid waste recycling expert, Beston Group has been committed to providing customers with integrated solutions. Meanwhile, we actively establish cooperation with customers around the world to jointly solve challenges in solid waste recycling. The long-term success of customers’ projects has always been the goal of Beston Group. Below are some successful cases of pyrolysis projects. If you want to know more about Beston Group, please follow us on LinkedIn.

Work with Beston Group

As the concept of sustainable recycling takes hold, continuous pyrolysis plant is seen as the future of solid waste recycling. We believe that cooperating with Beston Group on pyrolysis project will be an important step in promoting resource recycling. As a reliable manufacturer and professional solution provider, Beston Group provides customers with high-quality equipment and services. If you want to start a solid waste recycling business plan, don’t hesitate to join us.

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